Abstract: Embodiments provide systems and methods for utilizing acoustic sensors to detect defects via online or in situ monitoring of additive manufacturing (AM) processes. Sensors may capture acoustic waves associated with AM manufacturing operations. The acoustic emissions in combination with other sensing data, such as cameras or thermometers, may be used to characterize the state of the AM process, such as to detect a defect has occurred or confirm a defect has not occurred. When defects are detected, the AM process may be stopped to prevent further processing of a defective part. When defects are predicted as likely to occur, operational parameters of the AM device or process may be adjusted to mitigate the occurrence of a defect. The techniques disclosed herein enable detection of defects that occur underneath the surface of the part being manufactured, as well as correct issues with the AM device or process before a defect occurs.

Abstract: Embodiments provide systems and methods for utilizing acoustic sensors to detect defects via online or in situ monitoring of additive manufacturing (AM) processes. Sensors may capture acoustic waves associated with AM manufacturing operations. The acoustic emissions in combination with other sensing data, such as cameras or thermometers, may be used to characterize the state of the AM process, such as to detect a defect has occurred or confirm a defect has not occurred. When defects are detected, the AM process may be stopped to prevent further processing of a defective part. When defects are predicted as likely to occur, operational parameters of the AM device or process may be adjusted to mitigate the occurrence of a defect. The techniques disclosed herein enable detection of defects that occur underneath the surface of the part being manufactured, as well as correct issues with the AM device or process before a defect occurs.

Abstract: Embodiments of tuning fork-based sensors are disclosed. The sensors may include a measurement sensor that includes a diaphragm disposed on a proximal end and a plurality of forks extending from the diaphragm toward the distal end of the sensor. The diaphragm may have a domed geometry defining a curved surface. The plurality of forks may extending from the curved surface of the diaphragm toward the distal end and each of the plurality of forks may include a stub portion connected to the diaphragm, a stem portion, and a paddle portion. Some sensors, such as measurement sensors, may include a stem portion formed from a corrosive material. A reference sensor may be provided to compensate for changes in frequency measurements due to temperature, viscosity, or other environmental factors present in the environment where the sensors are deployed.

Abstract: Embodiments provide systems and methods for utilizing acoustic sensors to detect defects via online or in situ monitoring of additive manufacturing (AM) processes. Sensors may capture acoustic waves associated with AM manufacturing operations. The acoustic emissions in combination with other sensing data, such as cameras or thermometers, may be used to characterize the state of the AM process, such as to detect a defect has occurred or confirm a defect has not occurred. When defects are detected, the AM process may be stopped to prevent further processing of a defective part. When defects are predicted as likely to occur, operational parameters of the AM device or process may be adjusted to mitigate the occurrence of a defect. The techniques disclosed herein enable detection of defects that occur underneath the surface of the part being manufactured, as well as correct issues with the AM device or process before a defect occurs.

Abstract: Embodiments of tuning fork-based sensors are disclosed. The sensors may include a measurement sensor that includes a diaphragm disposed on a proximal end and a plurality of forks extending from the diaphragm toward the distal end of the sensor. The diaphragm may have a domed geometry defining a curved surface. The plurality of forks may extending from the curved surface of the diaphragm toward the distal end and each of the plurality of forks may include a stub portion connected to the diaphragm, a stem portion, and a paddle portion. Some sensors, such as measurement sensors, may include a stem portion formed from a corrosive material. A reference sensor may be provided to compensate for changes in frequency measurements due to temperature, viscosity, or other environmental factors present in the environment where the sensors are deployed.